CONCEPT OF

OC MINE PLANNING &

DESIGN

Mining Methods
Coal is mined by two main methods Surface or opencast mining and
underground mining.
The choice of method is largely determined
by the depth,thickness and no. of coal
seams, geology of the coal deposit and
other factors.

Mining Methods
Shaft Mine

Incline Mine

Incline

Excavator

Adit Mine

Opencast Mine

Ideal conditions for Opencast Mining

1.

Thickness of coal seams

> 5m

1.

Flat gradient

< 1 in 6

1.

Strike length

> 1 km

1.

No.of seams

Less the better, with

higher thickness

5.

Coal without stone bands

6.

Free from surface structures / features.

7.

Preferably non-forest land.

8.

Availability of adequate place for dumping.

9.

Stripping ratio depending on quality of the coal

General planning studies

No fixed procedure country-wise differences
1.

Conceptual study, data reliable upto

--

75%

Review
2.

Pre-feasibility study - data reliable upto

Additional data, modify
prepare, management acceptance

80%

3.

Feasibility Report/DPR - data reliable upto

85-90%

4.

Detailed designing LTP/MTP - data reliability

95%

5.

Operational planning (STP)

Basis for the initial study is Geological Report

There will be some overlap between various studies/reports.
Every step deals with Mining Technology, equipment, production
scheduling, capital cost, revenue cost, internal rate of return, dispatches etc.
However the degree of accuracy of data on the above aspects increases with
each step.
Generally After F.R. approval, there is need to go in for long term planning,
medium term planning (about 5 years) and S.T.P. Short-term planning (6
months one year).
These reports should adapt circular analysis approach by considering
various aspects like additional information available while operating the mine,
slippages occurred, reserves, pit-slopes, pit-limits, pit scheduling to control
faster rate of extraction from coal inventory which otherwise may lead to
reduction in coal production in subsequent years or more equipment for
higher OB removal to maintain targeted production.

CONCEPTUAL MINE PLANNING / PRE-FEASIBILITY

Deposit
Resources
GR/MR
Mining depth
Strata Sequa
Thickness of
- coal
- waste
- inter burden
Coal Quality
Slope stability
Water

Tech-Aspects

Economic aspects

Mining
Technology
Options and
Suggestions

Production requirements
Minelife requirements
Logistics,
Roads etc.

Equipment

Cash out flow

Cash inflow
Required rate of
Return
Cut-off SR

Surface
Constraints

Conceptual Mine Plan

(Open pit layout, equipment)
Modification of concept
and or optimization
Pre-Feasibility Study

Accepted
DPR

Management

Not accepted
New attempt

Steps in design of Opencast

A.
B.
C.
D.
E.
F.

Study of deposit exploration (GR)

Final pit limits.
Development sequence.
Design of Access Ramp and Haul Roads
Pit design
Annual production capacity system availability Mining
technology
G. Main Mining Equipment Matching to Mining Plan
H. Optimizing Dumping strategy and balancing
I. Year-wise / stage wise plans
J. Financial viability (Capital & Revenue)
K. Coal Washing
L. Environment stipulations

A. Study of GR on the deposit Exploration

Salient Information

Extent of deposit i.e. strike and dip rise widths.

Geology Geological succession, sequence of beds, drilling, logging, no. of

seams, sequence of coal seams, description.

Inter seam partings.

Structure No. of faults, Throws, dip of seams and beds

Reserves Quality wise/seam wise/depth-wise etc. based on Block model,

Gridded seam model & polygonal Model

O.B. volumes & S.R. Sector-wise, depth-wise etc.

Coal seam analysis, proximate and ultimate , Ash etc. & OB strata hardness etc.

Drilling details (Lithology)

Physiography

Climate and Vegetation

Preliminary EMP information

PLATES

A. Contd.

Location Map, Top Sheet map, Roads, Lands (Forests), Rivers etc.
Topography Hills, contours, rivers of Flats
Geological Map in crops, Faults
Graphic Lithologs
Graphic correlation charts
Floor/Roof contour plans of all seams
Seam folio plans of all seams (seam out cop, floor contours, faults,
isograde, isochore, iso depth).
Geological cross sections
Seam structure of all seams
ISO parting plans
ISO excavation plan for lower seam (surface constraints, boundaries,
faults at seam level, excavation area)

A. Contd.,

Additional Data required -Geo-technical data diggability of materials, slope geometry and stability of
Working/permanent slopes, spoil pile configuration
for outside/inside dump, stability, grainsizes after
blasting etc.
-Ground Water
hydrology

Dewatering and depressurization

- Impact of dewatering on surrounding areas
- Impact on water quality

-Surface hydrology - Water quality

- make off water
- Mine flood protection
- Options for discharge of dirty water and various
discharge systems.

B. Final pit limits

The criteria for delineation of boundaries of an Opencast Project are:
Rise side boundary

- Usually incrop of the bottom most seam

Lateral sides

- Usually by Geological disturbances like faults,

surface structures / features like nalah,
or limitation of the strike length of the deposits.

river etc
Dip side

- Depends on the economical stripping ratio,in

absence of natural constraints

B Contd.

B. Final pit limits

Final Pit limits
Haul analysis
Lead,lift increase cost decides mode of transport
Dump area 100m from mine boundary
Dump limits available are Dump area
50 m from internal access road.
Dump area 80-100 m. from mine
infrastructure
OB volumes
- Final slopes
Mineable Reserves various losses, batter, barrier etc.
- dilution etc (0-1 m against Roof,floor)
Maximum depth increases haul cost (30-40% of total cost at 1 1/2 Km lead.
Boundaries are drawn as above & Coal, OB ,SR are estimated

B Contd.

B. Final pit limits

Estimation of Coal, OB & Stripping ratio

Rough assessment is given below

Assuming Pit slopes of 450, the Quarry floor and Quarry surface are
delineated

Volume of Coal & OB

Average area

= (Quarry surface area + Quarry floor area) / 2

Average depth

= (Minimum depth + maximum depth) / 2

Volume of Coal=(Quarry floor area x Cumulative thickness of all coal

seams) - (B)

Coal in tonnes

OB Volume

= Average area x Average depth

- (A)

= Volume of coal x Specific gravity (C)

= Coal + OB Volume (A) Coal Volume (B) - (D)

Stripping ratio
= OB Volume (D) / Coal in tones (C)
For accurate S.R,the volumes of OB and coal are to be made seam wise

B Contd.

B. Final pit limits

The boundaries are firmed up based on the economic stripping ratio.

Economic stripping ratio varies with:
Average sales realization i.e. higher the quality of coal,
higher the realization.
Capital investment requirements
Operating cost.
Also surface constraints
The following thumb rules may be of some Help (with outsourcing OB removal):
Projects are likely to be economically viable upto a maximum SR indicated
against the grade of coal
Grade

Stripping ratio
(Cum/T)

10

C. Development Sequence
-Opening the deposit Access trench
-Box cut To accommodate all equipment
-Mine phases Depends on the shape of the property
-Progress of Benches
-Coal production schedules
-OB excavation schedules
Note:- Maximize inventory of coal in the initial years
-Differ OB stripping requirements as much as possible Average
SR versus natural SR
-Income generated in the first 5 to 10 years but not remote
economics will either make or break the project.
-Profits for in the future have practically no impact on the project NPV.
Each successive phase will be less profitable and the ultimate
limit will be loss even after ploughing in earlier profits.

D. Design of Access Ramp & Haul roads

Location of Access ramp is guided by the following:
1)

Generally located at the minimum depth of incrop of bottom most

seam So as to reduce initial waste stripping (unproductive work)

2)

Should facilitate maximizing of internal dumping and sectional

working.

3)

Should be near the External dump / Coal yard / Mine service

facilities etc.
Main haul road upto the pit limit should be planned in the
beginning only.
Since haul costs constitute about more than 40% and tyre costs
about 10% of the total mining costs,priority for design,construction
and maintenance should be given.
Gradient,width,drainage,curves,super elevation,base,sub
base,type and thickness of top dressing should be like that of
national high ways for heavy traffic.

4)
5)
6)

D. Design of Access Ramp & Haul roads

D Contd.

Haul roads
Sl.No

Particulars

Width

Should facilities two way traffic, dozer

movement, formation of drains, lighting
arrangement (Normal width 30m,but
depends on capacity of dumpers).

Gradient

1 in 16 Short ramps 1 in 10

Lesser number of
curves

In flat seams of
larger strike length

haul roads can be formed over the floor of

the seam

In steep seams

Haul road for Coal & OB benches can be

planned along highwall slopes say every
30m. This will also facilitate internal dumping.

E. Pit design.
General design parameters and planning data
Density of seams, total coal column thickness
Thickness of partings
Gradient
Geological disturbances
Strike lengths, shape of property
Geological Reserves
Surface constraints/adjacent habitat
Dump yards availability with lead and lift
Mining system, optimum mining concept
Depth of operation, mineable reserves after various losses, OB volumes, SR
Spoil characteristics
Work practices in the Area
Diggability characteristics

E Contd.

E. Pit design
As per Regulation 98 of CMR 1957,
In alluvial soil etc.

Sides shall be sloped at 450 or

Benched height not more than 1.5m
Width not less than height

In hard ground

Sides adequately benched/sloped so as

to prevent danger from fall of sides

Coal

Sides shall be sloped at 450 or

Benched height not more than 3m

However, exemption can be sought from Inspectorate.

E. Pit design

E Contd.

Overall slope of a pit depends on several factors of the pit slope:

a)

Geological disturbances like faults etc.

b)

Hydrological condition of strata

c)

Orientation of slip planes

d)

Nature of strata i.e. hardness, material consolidation etc.

e)

Depth of workings

f)

Design of haul roads & ramps in the highwall

g)

Stratigraphy thickness, spacing of the clay bands or other weak

layers

E. Pit design

E Contd.
In general for OC mines upto a depth of 200m, overall slope angle of 450 is
permitted.

E. Pit design

E Contd.

For deeper mines flatter highwall slopes will be necessary from safety point of
view (for 35 T dumpers & above)

E. Pit design

E Contd.

For deeper mines flatter highwall slopes will be necessary from safety point of
view (dumpers below 35T capacity)

E. Pit design
Typical High wall layout

E Contd.

E Contd.

E. Pit design
Working benches:
1) General
Width
Height

- 40 45m
- Generally equal to height of the boom or in some cases
upto 3m above the boom height.
In case of Backhoe digging height of machine
Bench slope - 560 to 700
2) Dragline:
Width of the cut
Height of bench

60m
maximum digging depth

3) In order to even out the yearly OB removal quantities and the

economics sometimes alternative workings and non-working benches
(around 25 m wide) are proposed.

F. Fixing annual production capacity

After defining the boundaries, the annual production capacity will be fixed
based on the following criteria :
1)

The available mineable coal reserves

2)

Geometry of the deposit -

3)

Structure of the deposit -

Strike & dip rise lengths

Thickness of seams, partings, faults,
gradient etc.

4) Linkage

Basket, Captive use etc.

5) HEMM configuration

Capacity of HEMM.

6) Surface structures

Limits the material to be blasted.

F Contd.

Excavator machine productivity

Based on ,
-Dipper cycle time
-Waiting time for truck spotting
-Bad blast factor
-Truck loading time etc.
Annual capacity is based on
-Equipment available hours
-Utilization percentage
Proper fragmentation,less throw off material,bench
height,bench slopes ,avoiding toes and secondary
blasting,improves shovel efficiency
Optimum fragmentation-cost of drilling,blasting vis-vis cost of dozing,loading,hauling and dumping.

F Contd.
System availability as a function of individual components
Calendar hours-(365x24)

(Figures are Indicative only)

Holidays and bad weather

2.5%-

Operational delays-blasting, relocations,shift

change,Lunch etc

1 Hour/Shift(8%)

Preventive maintenance-i.e annual,weekly,daily,shift

wise and unexpected break downs

15% of SSH
Availabilty-

Shovel,dumper system
12% - Crusher + 1 Conveyor

8760

scheduled working
hours(SSH)

100%

97%
85%

8463 / 6140

Scheduled operating time or

Equipment available hours

6563/4390

Effective Operating Time

6366/3960

Effective Operating Time

5559/3730

2% Drop for each Belt

73%
System Availability

4804/3160

G. Main mining equipment

For Various Technologies
1)

Shovel Dumper technology.

2)

Dragline technology

3)

Inpit Crusher conveyor spreader technology.

4)

Continuous Mining technology Bucket wheel excavators.

5)

Rock Breaker technology.

6)

Surface Miner technology.

G Contd.
Note: In seam Mining is always practiced in flat seams while in case of
steep seams Horizon mining, with its disadavntages, may have to be followed.

G. Main mining equipment

G Contd.

1)Shovel dumper technology:

This is the most commonly used technology in Opencast mines.

Basically two variants Rope shovels and Hydraulic shovels.

Shovel used for excavation & Dumper for transport of material.

Bucket capacities vary from 0.9 Cum to 40 Cum with matching

Trucks/Dumpers of 16 Cum to more than 240 T.

Can be deployed for removal of varying thickness of materials.

Harder materials require blasting.

Can be deployed for removal of steep & thin seams (hydraulic shovels).

G. Main mining equipment

G Contd.

2)Draglines:

A dragline bucket system consists of a large bucket which is suspended from a

boom with wire ropes.

Draglines are deployed wherever there is scope for side casting overburden
above coal seam into the de-coaled area.

It is very cost effective technology & can be deployed in flatter seams.

3)In pit crusher conveyor technology:
The drilled & blasted OB is loaded by shovels and transported by dumpers to
Crushers. The crushed OB is then transported by a series of conveyors into a
spreader for dumping.
Can be used in steep seams where laying of transport roads for the trucks is difficult.
While S.R indicates volumes,cut off ratio indicates depth and reflects in dumper
haulage cost,which increase with depth and may become prohibitive where in
alternative haulage system may have to thought off.
Ideally suited where material has to be transported over a large distance & lift.
4)Continuous Miner Technology:- Bucket Wheel Excavators
Presently being used in Neyvali, Lignite Opencast mines, having soft strata.
The buck wheel excavates the material without blasting which is transported by a
series of belt conveyors to spreader.

G Contd.

G. Main mining equipment

5)Rock breaker technology:

Rock breaker technology can be applied for breaking of rock/coal/ore

even about 500 kg/sq.cm.
It can be used wherever it is not possible to go for blasting near
vicinity of structures and habitations.
6)Surface Miner Technology:
Used for selective mining.
Larger strike length of about 600 m 1000 m and widths of around
300 m are ideally suited for surface miner.
Does not need drilling and blasting. The machine cuts the coal &
loads into trucks for onward transportation to Surface
Other common mining equipment to all the technologies
Drills
Dozers ,Graders & Compactors
Water Sprinklers
Pumps etc.
Electrical equipment
Crushers & Conveyors for Coal/OB

Rope Shovel & Dumper

Hydraulic Shovel & Dumper

An opencast mine with dragline

IN-PIT CRUSHER CONVEYOR TECHNOLOGY (Spreader in Operation)

Surface Miner

Rock breaker

H. Dumping strategy and balancing

Internal dumping:
Depends on the steepness of the seams.
As the gradient increases, the percentage of dumping reduces.
Internal dumping can be increased by sectorial working of the pit which may
reduce the annual output.
Toe of the dump generally kept at a distance of 100 m from the working benches.
Floor of the pit to be roughened by blasting for increasing dump stability.
General design of dumps:
Deck height 30m
Berm width 30m
Deck slope 370
Overall slope 280
Swell factor for OB-1.38,for coal 1.40
Swell compact after initial settling 1.20
Note:-Dump yard management and control is essential for the success of open cast
mining. In case of more than one External Dump yards, balancing the excavation
volume to either of the dump yard should be based on lead & lift and size of the
Dump yards.

H Contd.

H. Dumping strategy

1.
1.
2.
2.
3.
3.
4.
4.
5.
5.

Total dump height- 90m

Total dump height- 90m
Deck height 30m
Deck height 30m
Berm width 30m
Berm width 30m
Deck slope-37 0
Deck slope-37 0
Overall slope-280
Overall slope-280

H Contd.

H. Dumping strategy

1.
1.
2.
2.
3.
3.
4.
4.
5.
5.

Total dump height- 90m

Total dump height- 90m
Deck height 15m
Deck height 15m
Berm width 15m
Berm width 15m
Deck slope-37 0
Deck slope-37 0
Overall slope-24.830
Overall slope-24.830

H Contd.

Internal Dumping reduces with the increase in the gradient of the seam.

Comparison between 1in4 and 1in8 Gradient

floor dipping at 1in8

floor dipping at 1in4

Assumptions:

Strike Length
Max. Depth
Coal Seam thickness
Annual Rated capasity

Project Parameters

Area of Excavation
Mineable Reserves
Total OB Removal
Stripping Ratio
Life of the Project
Volume of Internal Dumping
Volume of External Dumping
% of Internal Dumping
(upto Ground Level)

:
:
:
:

:
:
:
:
:
:
:
:

1000m
110m
15m
6.0 LTPA

1in4

0.59 Sq.km
90.0 L.T
274.0 L.m3
2.74
17 Years
39.85 L.m3
234.15 L.m3
14.54

Safe distance from coal bench

to toe of internal dump
: 100m

1in8

1.04 Sq.km
180.L.T
480.5 L.m3
2.67
32 Years
256.41 L.m3
134.00 L.m3
53.36

50m

I. Designing the year-wise / stage wise plans

I) Stage plans

Stage plans are prepared based on Year-wise production

requirements (rated out put)

Stage plans at the end of years 1, 2, 3, 4, 5 & in intervals of 5

years are prepared.

Also plans are prepared where any specific land mark like a new
box-cut, change in layout will take place.

J. Financial Viability
1)
2)

The requirement of HEMM & its capital is estimated.

Other capital like developmental works, CHP etc are worked

out.
3) Operating expenses are worked out to arrive at cost of
production.
4) Financial viability including profit & loss , IRR etc is
estimated.
5) Based on required IRR, anticipated selling price is also
worked out.

K. Coal Washing
Need for Washing
Power Houses consume about 75% of coal.
Power Houses are designed to accept Coal of E Grade & above
(UHV>3300).
The percentage of production of coal below E Grade is increasing .
MoEF stipulation Presently the onus of responsibility is on end user for
using Coal of not more than 34% ash if he is located over 1000Km away.
Hence, the need to upgrade coals below E Grade so as to suit the
requirements of Power houses.
Cost of washing is around Rs 120-130/T of raw coal.

L. Environment stipulations
As per EP Act 1986
Environment
includes water, air and land and the inter-relationship
which exists among and between water, air and land and
human beings, other living creatures, plants, micro
organism and property

 Air

Impacts and Mitigative Measures

L Contd.

Impacts: Dust is generated from drilling, blasting,

excavation, crushing and transportation operations. This
dust becomes air borne and gets carried away to
surrounding areas.

Mitigative Measures:
Extensive water spray arrangements at the Coal
handling sites.
Wet-drilling methods are to be adopted.
Water spraying on haul roads and permanent transport
routes at required frequencies. Provision for mobile
water sprinklers has to be made for this purpose.
Extensive Green Belt development around the quarry
and OB dump
Black topping the transport routes and avenue
plantation on these roads.

Water spraying on the haul road

Continuous water spraying on the haul road

Impacts and Mitigative Measures

L Contd.

Water:
Impacts:
Pollution of the surface water bodies with the
mine discharge water and domestic sewage.
Mitigative Measures:
The Mine Discharge water is to be treated in
settling tanks before discharging it into the
surface water bodies.

Effluent from workshop is to be treated in ETPs.

Sewerage treatment plant to be provided for

treating the domestic sewage from the colony.

Photograph of STP

Treatment plant for Work shop effluent

Impacts and Mitigative Measures

Noise Pollution &
Vibrations
Impact

L Contd.

The main sources of noise in the project are electrical and

diesel-powered machines, compressors, pumps, drilling
machines, dumpers, etc.
During blasting operations blast vibrations will take place.

Control Measures

Controlled blasting techniques using NONELs are to be

adopted .
Creation of green belts of dense foliage in three rows
between mine areas and residential colonies.
Proper maintenance of machinery including transport
vehicles.
Protective devices like earplugs and earmuffs are to be
provided to the needy workers.
Sound and dust proof cabins are to be provided in the
machines like dozers, shovels, dumpers and feeder
breakers at CHP etc.

Impacts and Mitigative Measures

L Contd.

Over Burden Management

Topsoil excavated from the quarry is to be dumped
separately at predetermined place and has to be
subsequently spread on external dumps for plantation.

Top soil dump is to be kept not more than 10m height.

Top soil has to be vegetated with grasses and

leguminous species to maintain its fertility.

The reclamation of O.B dumps is to be done by using

Biological Engineering techniques for stability of slopes
and prevention of soil erosion from O.B dumps.

Construction of crib structures, Gabion structures,

forming of staggered Contour trenches are to be
practiced for stability of slopes.

Impacts and Mitigative Measures

L Contd.

Over Burden Management

Raising of seedlings on both top and slopes of the dumps

in the staggered contour trenches.

By dibbling seeds of various species like Avisa, Subabool,

Babul, Neem etc.

Safe disposal of rainwater by construction of garland

drains. Garland drains are to be provided around the
quarry and overburden dumps .

Safe disposal of water from Top of OB

Thank you all,